DESIGN, ANALYSIS AND OPTIMIZATION OF BRAKE DISC MADE OF COMPOSITE MATERIAL FOR A MOTOR CYCLE

NOVATEUR PUBLICATIONS International Journal of Research Publications in Engineering and Technology [IJRPET] ISSN: 2454-7875 VOLUME 3, ISSUE 3, March-2017

DESIGN ANALYSIS OF LOWER CONTROL ARM OF MAC PHERSON SUSPENSION SYSTEM MR.SWAPNIL S. KHODE Student Dept. of Mechanical, Dr. D. Y. Patil School of Engineering, Lohagaon Pune, India, swapnilskhode@gmail.com PROF. AMOL B. GAIKWAD Dept. of Mechanical, Dr. D. Y. Patil School of Engineering, Lohagaon Pune, India, amol.gaikwad@dypic.in ABSTRACT: The most important component in vehicle is suspension system, which directly affects the safety, performance and noise level. Suspension arm is one of the most important components in the suspension system. It is fitted in various types of the suspensions like Macpherson, wishbone or double wishbone suspensions. The lower control arm is a wishboneshaped metal strut that attaches the wheel to the vehicle's frame. In order to determine the deformation and stress distribution in the current design, the finite element analysis is carried out. The baseline model of the lower control arm is created by using solid modeling software viz. CATIA. ANSYS Workbench is used for Finite Element Analysis This study deals with Finite Element Analysis of the Lower control arm of Mac-pherson suspension system.

KEYWORDS: LCA, FEA, Mac-pherson.

surface irregularities .Semi rigid suspensions system shows intermediate characteristics between the other two categories [2].

INTRODUCTION: Vehicle suspension system fulfils various purposes. It provides a vertical obedient element between un-sprung and sprung mass in order to maintain contact between ground and wheel, by reducing the sprung mass motion. It maintain proper attitude of the vehicle during various operating conditions like braking, cornering, accelerating. It also road holding and steering characteristics. Overall performance of suspension system is limits on maximum suspension travel, transmissibility of forces, road holding, minimum weight and cost[1]. There are three different types of suspensions namely: Dependent (Rigid Axle), independent and semi-independent suspensions.

In the independent suspension system, there are no linkages between two hubs of same axle and it allows each wheel to move vertically without affecting the opposite wheel. This system has inherent advantages over dependent system such as more space for engine, better roll resistance, lesser un-sprung weight and better resistance to steering vibration. Dependent suspension or rigid axles provide a solid connection between two wheels of the same axle. Therefore motion of one wheel is transferred to the other wheel while travelling along

Fig. 1 Classification of Wheeled Suspension A. PROBLEM DEFINITION: The design of a suspension system is very important. When the vehicle passes on road, it exhibits the impact loads. We experience the sudden motion along with the vehicle; it is very uncomforted to the passengers. The design of a suspension system comes into the picture under this scenario’s.

There is absence of balance rod in recent modified Indian light commercial vehicle, which is part of suspension system. Balance rod act as a supportive member for lower control arm of suspension system.

Due to absence of balance rod maximum stresses are transferred to lower control arm.

B. OBJECTIVE: In order to solve above mentioned problem, main aim of the project is summarize below:  To carry out strength evaluation of lower control arm of one of the Indian light commercial vehicle.  To carry out reverse engineering on existing model and prepare 3D model using CATIA software.

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NOVATEUR PUBLICATIONS International Journal of Research Publications in Engineering and Technology [IJRPET] ISSN: 2454-7875 VOLUME 3, ISSUE 3, March-2017 W =13243.5 N  To carry out static structural analysis of existing It is assumed that 52% of weight taken by front model using FEA based software ANSYS axle, due to mounting of engine on front side and workbench. remaining 48% weight taken by rear axle. Therefore,  Weight on Front axle = 0.52*13243.5 N C. METHODOLOGY: F1= 6886.62 N Weight on Rear axle = 0.48*13243.5 N F2 = 6356.88 N Reaction at each front wheel Rw= Weight on Front axle/2 Rw = 6886.62/2 Rw =3443.31 N This load is constituted by spring, axle and lower control arm.

While stub axle of the wheel takes 50% of the total load acting on each wheel.

Therefore, force acting on the front axle of wheel is given II. THEOROTICAL ANALYSIS: by, A. DIMENSION OF LOWER CONTROL ARM: F= 1721.6 N Following line diagram is a representation of the spring, axle, and lower arm.

Fig. 2. Dimension of Lower Control Arm Dimension of Lower Control Arm is as follows: Length:463mm Height:241.9mm B. MATERIAL PROPERTIES: Lower control arms have to withstand high load carrying capacity.

This material is in existing component. The Material should have higher the yield point, elasticity, buckling strength, etc. The material is AISI 1040, which is having all these characters.

TABLE I. MATERIAL PROPERTIES Sr.No.

Description

1 2 3 4

Modulus of Elasticity, MPa Poisson’s Ratio Yield Strength, MPa Density, Kg/m3

Values 2e5 0.3 800 7850

C. STATIC LOAD CALCULATION OF LOWER CONTROL ARM: Gross Weight of Wagon R =1350 Kg (considering passengers and accessories weight) Total Weight in Newton = 1350*9.81

Fig.3. Line diagram for force distribution Where, R1=Reaction for spring in Newton.

R2=Reaction for lower arm in Newton.

F = Force acting on stub axle in Newton Therefore, from equilibrium condition, taking moment at A is equal to zero. ∑MA = 0 F2 *100- R2*225 = 0…………………………..(1) 1721.6 *100 =R2*225 R2 = (1721.6*100)/225 R2 =765.15 N This is vertical load acting on the lower control arm.

Now, R1 + R2 =F2 R1 = F2 – F1....................................(2) R1 =1721.6-765.15 R1 =956.45 N This reaction is acting vertically upward at spring.

Therefore, the Reaction R2 = 765.15 N Approximately taken as R2 ≈ 765 N, which is acting in vertically downward direction on lower control arm.

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NOVATEUR PUBLICATIONS International Journal of Research Publications in Engineering and Technology [IJRPET] ISSN: 2454-7875 VOLUME 3, ISSUE 3, March-2017 III. MODELING OF LOWER CONTROL ARM: A. MESHING OF BASELINE GEOMETRY: CAD software like CATIA is higher end software The conventional model which was developed in which is feature based solid modelling systems. CATIA CATIA software has to be meshed for analysis. For this V5R22 is used for modelling of Lower Control.

ANSYS workbench software is used. It is a highA. “2DMODELING” OF EXISTING LOWER CONTROL performance finite element pre-processor that provides ARM: a highly interactive and visual environment to analyze product design performance. With the broadest set of direct interfaces to commercial CAD and CAE systems.

The solid tetrahedron elements are used to generate the meshing of the control Arm.

Fig.4. ‘2D’ Views of Lower Control Arm B. “3DMODELING” OF EXISTING LOWER CONTROL ARM:

Fig. 8. Meshing of Lower Control Arm

Sr. No. 1 2 3

TABLE II. DETAILS OF MESHING Description Values Number of Nodes 53002 Number of Elements 26694 Element Size Max. 5 mm, Min. 3 mm

Fig. 5.Top View 3D of Lower Control Arm B. DESIGN PARAMETERS: In case of vehicle in actual running conditions forces acting on it are of dynamic in nature and changes as per driving conditions. Various longitudinal forces are acting due to braking and acceleration while lateral forces acting due to cornering of vehicle. In order to make preliminary analysis steady state operating conditions are assumed. The assumptions made are smooth road conditions, steady state cornering and constant grade.

Fig. 6. Back View 3D of Lower Control Arm IV. FINITE ELEMENT ANALYSIS: ANSYS software is used to mesh the solid model. Cad model which is in IGES format is imported to ANSYS.

C. BOUNDARY CONDITIONS OF BASELINE GEOMETRY: Wheel is mounted on stub axle which is connected to steering knuckle. This steering knuckle has three arms let say upper arm, lateral arm and lower arm.

Upper arm is connected vertical helical coil spring strut , lateral arm is connected to tie rod of steering mechanism and lower arm is connected to wishbone or lower control arm by a ball joint. Other two end are connected to chassis frame, out of which one is fixed and other end turn about a pivot.

Fig. 7. Baseline Lower Control Arm for FEA

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NOVATEUR PUBLICATIONS International Journal of Research Publications in Engineering and Technology [IJRPET] ISSN: 2454-7875 VOLUME 3, ISSUE 3, March-2017

Fig. 9. Connection of Lower Control Arm

Fig.12(a). Equivalent Stress Plot

Fig. 10. Boundary conditions of lower control arm.

Fig.12 (b). Equivalent Stress Plot

D. ANALYSIS RESULT OF BASELINE MODEL: After Finite Element analysis on ANSYS workbench 14.5 following results have been find out. The displacement contour plots are shown in the below figure. The maximum displacement shown by the control arm is 10.74 mm. As per distortion energy theory, the maximum equivalent stress observed in the lower arm model 677 MPa. The yield strength of the material is 800 MPa. According to results, the von-Mises stress 677 MPa is greater than yield strength of the material. The factor of safety of the baseline lower Arm is 1.18.

V. RESULT AND DISCUSSION: It is observed from the results that maximum stresses are developed at sharp corners and hole of the lower control arm.

TABLE III. Sr. No. 1 2 3

Method

FEA Method

RESULTS

Description

Baseline Design

Deflection, mm

10.74

Von-Mises stress, MPa Mass, Kg

677 1.20

ACKNOWLEDGMENT: I am thankful to Prof. A. B. Gaikwad and Prof.

Amol Patil in Mechanical Engineering Dept., DYPSOE, Pune for his encouragement and support to carry out this work .

Fig. 11.Maximum deformation Plot The following figure shows contour plot of the vonMises stress.

REFERENCES: 1) Himanshu Deshwal, Rahul Jangid, “Finite Element Analysis and Geometric Optimization of Double Wishbone Pushrod Actuation Suspension System of “SUPRA SAEINDIA” Vehicle” SSRG International Journal of Mechanical Engineering (SSRG-IJME) – volume 3 Issue 5 – May 2016 2) Mr. Prashanthasamy et al. “Design and Modal Analysis of Lower Wishbone Suspension Arm Using FE Approach” Imperial Journal of Interdisciplinary Research (IJIR) Vol-2, Issue-9, 2016

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NOVATEUR PUBLICATIONS International Journal of Research Publications in Engineering and Technology [IJRPET] ISSN: 2454-7875 VOLUME 3, ISSUE 3, March-2017 3) Sagar Darge, S.C. Shilwant, S. R. Patil “Finite Element Analysis and Topography Optimization of Lower Arm of Double Wishbone Suspension Using Abacus and Optistruct” Sagar Darge et al Int. Journal of Engineering Research and Applications.

4) Roslan Abd Rahman, Mohd Nasir Tamin, Ojo Kurdi “Stress analysis of heavy duty truck chassis as a preliminary data for its fatigue life prediction using FEM” Jurnal Mekanikal December 2008, No. 26, 76 – 85.

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